Tesla TI15014-120-240, TI15028-120-240 User Manual

TI150 Series Battery

Power Anytime, Anywhere

Charger/Conditioner

TI15014-120-240 (12V)
TI15028-120-240 (24V)

User Manual

Built Smart...Proven Tough

Tesla Industries, Inc.

101 Centerpoint Blvd.
New Castle, DE 19720
[phone] Phone
[phone] Fax

www.teslaind.com

NOTE: All users must read this entire manual prior to operating

the TI150 Series Battery Charger/Conditioner.

The TI150 Battery Charger/Conditioner is a limited maintenance-free and sealed unit. No repairs are au­thorized. Warranty will be voided if unit is tampered with in any way, or if unauthorized repairs are made.
For technical support please contact:

TESLA™ INDUSTRIES INCORPORATED

101 CENTERPOINT BLVD.

CENTERPOINT INDUSTRIAL PARK

NEW CASTLE, DELAWARE 19720

PHONE: [phone]

FAX: [phone]

WEBSITE: www.teslaind.com

EMAIL: [e-mail]

CAUTION

Improper use or failure to follow instructions in this user manual can result in unit damage and/or injury or
death by electrical shock.

Any attempts to open or examine the inside of this unit via a tool or device (borescope, probe, etc.) can
result in unit failure and/or injury by electrical shock. This unit is mainte nance free and should not be
opened or disassembled for any reason.

Always protect the unit from short circuit.

Shipping Hazards: NONE

No part of this manual may be reproduced or transmitted in any form or by any means, electronic or
mechanical, including photocopying, recording, or any information storage and retrieval system, without
prior written permission from Tesla™ Industries, Inc.

Shock Hazard Potential

Copyright © 2014 by Tesla™ Industries, Incorporated. All rights reserved.

06-05-14

Table of Contents

Section 1 – Safety Review 1

1.1 – Safety Notices 1

1.2 – Symbols 1

1.3 – Water Hazards 2

1.4 – Important Safety Precautions 2

Section 2 – Product Overview 3

2.1 – Introduction 3

2.2 – Indication of Terms: Shall, Should, and May 3

2.3 – Front and Top Panel Overview 4

2.4 – Physical Dimensions 5

2.5 – General Specications 6

2.6 – Airow Ports 7

Section 3 – Features Overview 8

3.1 – AC Input Receptacle 8

3.1a – IEC Line Cord Options 8

3.2 – AC Input Selector Switch 8

3.3 – AC Input Circuit Breaker 9

3.4 – DC Output Cable 9

3.5 – DC Output Circuit Breaker 9

3.6 – Charge Level Indicator 10

3.7 – Integrated Heatsinks 10

3.8 – Mounting Base 10-11

Section 4 – Pre-Operation Procedures 12

4.1 – Installing the Charger 12

4.2 – Attaching AC Power 12

4.3 – Attaching the DC Power Cable 13-14

TI150 Series Battery Charger/Conditioner

Section 5 – Operating Procedures 15

5.1 – Unit Care 15

5.2 – Connecting the Battery Charger 15

5.3 – After Operation 15-16

Section 6 – Unit Care and Maintenance 17

6.1 – Unit Care 17

6.2 – Normal Function Test Procedures 18-19

6.3 – Unit Servicing 20

6.4 – Packaging and Shipping 20

Section 7 – Frequently Asked Questions 21

Section 8 – Troubleshooting 22-23

Section 9 – Optional Accessories 24

9.1 – TI2007-013 Mini NATO Quick Disconnect Cable Assembly 24

9.2 – TI2007-019 Mini DC to 10AWG Quick Disconnect Cable Assembly 24

9.3 – Cobra™ DC Replacement Contacts and Tools 24

Section 10 – Performance Data 25

10.1 – Purpose 25

10.2 – Explanation of Data 25

10.3 – Denition of Abbreviations 25

10.4 – Performance Graph 25

10.5 – Temperature Conversion Chart 26

Glossary 27
Repair Request Form 28

TI150 Series Battery Charger/Conditioner

Abbreviations and Symbols

Abbreviations that may be used within the text, headings and titles of this manual.

LIST OF ABBREVIATIONS

Abbreviation Defi nition

ac Alternating Current

AFT Air ow Technology

AWG American Wire Gauge
amp or A Ampere
cont Continuous
°C Degree Celsius
°F Degree Fahrenheit
dc Direct Current

EFF Ef ciency

ft Feet
FWD Forward
GPU Ground Power Unit
Hr Hour
Hz Hertz
kg Kilograms
kHz Kilohertz
kW Kilowatts
LED Light Emitting Diode
max Maximum

MΩ megaohm

min Minimum
MPU Micro Power Unit
NEMA National Electrical Manufacturers Association

Ω ohm

PF power factor
PFC power factor correction
rms root-mean-square
THD Total Harmonic Distortion
TMDE Test, Measurement, & Diagnostic Equipment
UAV Unmanned aerial vehicle
Vac Volts, Alternating Current
Vdc Volts, Direct Current
W watts

TI150 Series Battery Charger/Conditioner

Figure 1.2.1 – Different types of hazard and caution symbols

1.1 - Safety Notices

Safety notices appear throughout this manual to alert the user to important information regarding proper
installation, operation, maintenance and storage of the unit. These notices, as illustrated below, contain a

key word that indicates the level of hazard and a triangular icon that indicates the speci c type of hazard.

WARNING

Indicates a condition, operating procedure or practice, which if not
adhered to could result in serious injury or death.

CAUTION

Indicates a condition or operating procedure, which if not strictly
adhered to could result in damage or destruction of equipment.

NOTE

Indicates a condition, operating procedure or practice, which is
essential to highlight.

1.2 - Symbols

The following symbols will appear within the warning triangles to alert the user to the speci c type of danger

or hazard.

General Warning Electrical Hazard Explosion Hazard Fire Hazard

Battery Warning Guard from Moisture

!

Section 1 – Safety Review

!

!

!

TI150 Series Battery Charger/Conditioner

1

1

Safety Review

1.3 – Hazards

WARNING

Severe injury or death from electrical shock will occur if either the user or the TI150 Battery Charger/
Conditioner is wet while operating the unit with the 120 or 240 Vac plug attached. Be sure to discon nect
ac power from the ac outlet if the TI150 Battery Charger/Conditioner has come into contact with water.

If the DC Output Circuit Breaker has tripped due to water inltration, DO NOT try to reset it with the unit

plugged into line voltage. Follow standard procedures for resetting the DC Output Circuit Breaker under
Section 3.5.

WARNING

Severe injury or death from electrical shock can occur when damp electrical connections from the TI150

Battery Charger/Conditioner are plugged into ac line voltage. See Section 6.1 for standard procedures in

wet conditions.

CAUTION

Shock Hazard Potential

Shock Hazard Potential

Unit Damage Potential

Damage may occur if the TI150 Battery Charger/Conditioner is operated after exposure to moisture (rain,

fog, snow, etc.). If water inltration is suspected, DO NOT CONNECT to ac voltage. Move the unit to a non-

humid location and allow it to dry for a minimum of one (1) hour before operating again. DO NOT USE the

unit if the exterior is damp. See Section 6.1 for standard procedures in wet conditions.

1.4 – Important Safety Precautions

WARNING

Severe injury or death from re or explosion can occur if electrical sparks are produced near fuel vapors.
Make sure the TI150 Battery Charger/Conditioner is at least 20 feet (6 meters) away from the nearest

fueling source before connecting either the ac or dc power cables.

Fire/Explosion Hazard Potential

2

TI150 Series Battery Charger/Conditioner

Section 2 – Product Overview

2.1 – Introduction

Thank you and congratulations on the purchase of your new TI150 Series Battery Charger/Conditioner.

This manual contains the complete operating instructions and procedures for the TI150 Series Battery
Charger/Conditioner models: TI15014-120-240 and TI15028-120-240. The TI150 Battery Charger/
Conditioner has been designed to rapidly recharge any 12 or 24 volt battery, depending on the model.
Both models incorporate an intelligent recharging circuit that prevents overcharging and provides pure dc

output for efcient battery charging and conditioning.

The TI150 Battery Charger/Conditioner is encased in a rugged enclosure, and is designed to be used as a

free standing unit, or to be mounted to a vehicle or other xed object using the integrated mounting base.

Both models include a detachable line cord and two interchangeable dc output cables (ring terminals for
direct battery connection or alligator clamps for rapid connect and disconnect. See Figure 2.1.1). Each
model’s capabilities and requirements are listed below:

 •Model TI15014-120-240 accepts both 120 Vac or 240 Vac and charges 12V batteries

 •Model TI15028-120-240 accepts both 120 Vac or 240 Vac and charges 24V batteries

Figure 2.1.1 – TI150 Series Battery Charger/Conditioner IEC

2.2 – Indication of Terms: Shall, Should, and May

Within this technical manual the word “shall” is used to indicate a mandatory requirement for proper
operation and warranty purposes. The word “should” is used to indicate a non-mandatory but preferred
method of accomplishment. The word “may” is used to indicate an acceptable method of accomplishment.

TI150 Series Battery Charger/Conditioner

3

2

Product Overview

2.3 - Front and Top Panel Overview

11

10

9

8

7

6

1

5

2

3

Mounting Base –1) Allows mounting of the TI150 series Battery Charger/Conditioner via four mounting holes.

AC Input Receptacle 2) – Connects to standard ac cable (Included with both the TI15014-120-240 and TI15028-

120-240).

AC Input Selector Switch 3) – Allows manual selection of either 120 Vac or 240 Vac Input voltage (see Sec-
tion 4.2 for proper selection).

Quick Disconnect Connector 4) – TI2010-095 12/24 V Cable Assembly with female connector.

DC Output Cable 5) – Provides 14.25 Vdc @ 20 A max (TI15014-120-240) or 28.5 Vdc @ 10 A max

(TI15028-120-240).

AC Input Circuit Breaker 6) – Protects the internal electrical circuit from damage caused by overload or short
circuit. Acts as an “On/Off” switch for the Battery Charger/Conditioner.

4

DC Output Circuit Breaker 7) – Trips if an over current condition occurs (30 amps for TI15014-120-240, and
15 amps for TI15028-120-240).

Air Exhaust Ports – 8) Expel heated air drawn in by Cooling Fan.

Integrated Heatsinks – 9) Provide additional cooling under heavy loading conditions.

Charge Level Indicator10) – Displays current battery charge level when connected to a battery.

Cooling Fan11) – Provides continuous airow for cooling internal circuitry (only when under a load.)

4

TI150 Series Battery Charger/Conditioner

3.50 [88.9]

4.68 [119.0]

5.68 [144.3]

2.4 – Physical Dimensions

12.37 [314.3]

9.03 [229.3]

Product Overview

2

Measurements are in inches and millimeters

Figure 2.4.1 – TI150 Battery Charger/Conditioner Physical Dimensions

TI150 Series Battery Charger/Conditioner

5

2

Product Overview

2.5 – General Specications

Input

Operates from Single Phase 100-260 Vac / 40-500 Hz•

4.7 amps @ 120 Vac 60 Hz•

2.35 amps @ 240 Vac 60 Hz•

Output

Models TI15014-120-240 (12 Vdc Output)•

- 20 amps continuous @ 14.25 Vdc (when plugged into ac power)•
Models TI15028-120-240 (24 Vdc Output)•

- 10 amps continuous @ 28.5 Vdc (when plugged into ac power)•

Frequency

50-450 Hz•

Temperature Ratings

Operating temperature: -40°F to +140°F (-40°C to +60°C)•
Storage temperature: -85°F to +140°F (-65°C to +60°C)•

Physical Specications

Dimensions: 13.37” L (314.3 mm) x 5.68” W (144.3 mm) x 3.50” H (88.9 mm)•

Weight: 4.11 lbs (1.87 kg)•

Warranty

2 Years (3 Year Optional)•

6

TI150 Series Battery Charger/Conditioner